Totally integrated engine cooling module for D.C. motors

ABSTRACT

An engine cooling module includes a shroud structure  12.  A housing  20  of a d.c. electric motor is formed integrally with the shroud structure  12.  The housing has an open end  21.  The motor has a drive shaft  26.  A heat sink  22  is disposed opposite the open end and is insert molded with respect to the housing  20.  The heat sink  22  defines a seat for a bearing  24  supporting the shaft  26.  A flux ring assembly  48  is insert molded with respect to the housing. The flux ring assembly includes permanent magnets  33.  An armature assembly  28  is disposed in the housing and fixed to the shaft for rotation in response to a magnetic field generated by the magnets  33.  A commutator  32  is disposed in the housing and electrically connected with the armature assembly  28  and mounted for movement with the armature assembly. A brush card assembly  36  is coupled to the open end  21  of the housing to define an end cap covering the open end. The brush card assembly  36  has brushes  42  associated with the commutator  32.  A fan  16  is coupled to the shaft  26  for rotation therewith.

This is a divisional of application Ser. No. 09/551,442, filed Apr. 18, 2000, which is hereby incorporated by reference.

This application claims the benefit of U.S. Provisional Application 60/164,400, filed Nov. 9, 1999, which is hereby incorporated by reference in its entirety herein.

FIELD OF THE INVENTION

This invention relates engine cooling modules for automotive applications and more particularly to a cooling module having fewer parts and are therefor easier to manufacture and assemble.

BACKGROUND OF THE INVENTION

Typical cooling modules for vehicle engines generally include three separate parts: a fan, an electric motor to drive the fan, and a shroud to direct air flow and to mount the module. Due to the need for separate parts, many subassemblies need to be performed to complete the final assembly of the module. Further, since the motor is separate from the shroud, the motor requires a case and end caps at both ends thereof which increases the weight of the module.

In certain applications, due to space and environmental constraints, it is desirable to provide an engine cooling module of reduced axial length and, to reduce costs, having reduced number of module parts.

Accordingly, there is a need to provide an improved cooling module for an electronically controlled engine which has a motor integrated with a fan and a shroud to provide a module having a reduced axial length and fewer parts.

SUMMARY OF THE INVENTION

An object of the present invention is to fulfill the need referred to above. In accordance with the principles of the present invention, this objective is obtained by providing an engine cooling module including a shroud structure. A housing of a d.c. electric motor is formed integrally with the shroud structure. The housing has an open end. The motor has a drive shaft. A heat sink is disposed opposite the open end and is insert molded with respect to the housing. The heat sink defines a seat for a bearing supporting the shaft. A flux ring assembly is insert molded with respect to the housing. The flux ring assembly includes permanent magnets. An armature assembly is disposed in the housing and fixed to the shaft for rotation in response to a magnetic field generated by the magnets. A commutator is disposed in the housing and electrically connected with the armature assembly and mounted for movement with the armature assembly. A brush card assembly is coupled to the open end of the housing to define an end cap covering the open end. The brush card assembly has brushes associated with the commutator. A fan is coupled to the shaft for rotation therewith.

In accordance with another aspect of the invention, a method of providing an engine cooling module includes: integrally coupling a motor housing to a shroud structure via a molding process, the housing having an open end; insert molding a heat sink with respect to the housing to be fixed thereto opposite the open end, the heat sink defining a bearing seat for a bearing of the motor, the bearing supporting a drive shaft, insert molding a flux ring assembly with respect to the housing so as to be fixed thereto, the flux ring assembly including permanent magnets; mounting an armature assembly and commutator for movement with the shaft in response to a magnetic field generated by the magnets; coupling a brush card assembly to the housing so as to cover the open end, the brush card assembly including brushes associated with the commutator, and coupling a fan to the shaft.

Other objects, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a engine cooling module as seen from the rear thereof, provided in accordance with the principles of the present invention;

FIG. 2 is an exploded view of the engine cooling module of FIG. 1 as seen from the front thereof;

FIG. 3 is an exploded view of a motor and bush card assembly of the module of FIG. 1 as seen from the front thereof; and

FIG. 4. is an exploded view of the motor and brush card assembly of FIG. 3 as seen from the rear thereof.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, an engine cooling module is shown in exploded view, generally indicated 10, provided in accordance with the principles of the present invention. The cooling module 10 includes a shroud structure 12 formed preferably of lightweight material such as plastic. In the conventional manner, when assembled, the shroud structure 12 is spaced from and generally adjacent to blades 14 of a fan 16 of the module 10.

The module 10 includes a dc electric motor, generally indicated at 18, having a housing 20 having an open end 21. The housing 20 is made of steel and over-molded, via molding material, to the shroud structure 12 so as to be integral therewith. The housing 20 is supported generally centrally of the shroud structure 12 by rib members 23. The motor 18 includes a heat sink 22 insert molded with respect to the housing 20 at an end opposite the open end 21. Thus, during a molding process material is molded about the heat sink 22 so that the heat sink 22 is made integral with the housing 20. The heat sink 22 also provides a seat for a ball bearing 24 of the motor 18 and provides for heat dissipation from the bearing 24. The bearing 24 supports an end 25 of a drive shaft 26.

As best shown in FIG. 2, the motor 18 includes an armature assembly, generally indicated at 28, mounted for rotation with shaft 26. The armature assembly 28 includes a steel core member 30 which may be solid member or may be comprised of a plurality of laminations in the conventional manner. The armature assembly 28 includes a conventional winding set (not shown) wound about the core member 30. The shaft 26 is fixed to the core member 30. Armature assembly 28 is in electrical contact with a commutator 32 and rotates in response to a magnetic field generated by permanent magnets 33 (FIG. 4) of the motor 18. The commutator 32 is mounted for movement with the armature assembly 28.

A disked-shaped brush card assembly, generally indicated at 36, is snap-fitted to the housing 20. In particular, with reference to FIG. 3, the brush card assembly 36 has a plurality of tabs 38 which engage associated recesses 40 (FIG. 4) defined in the motor housing 20 so that the brush card assembly 36 covers the open end 21. The brush card assembly 36 carries a plurality of brushes 42 extending from a surface 44 thereof. DC current is fed into the winding set through the brushes 42 riding on the commutator 32. The brush card assembly 36 also includes a sleeve bearing 46 which supports end 47 (FIG. 4) of the shaft 26. Openings 49 in the brush card assembly 36 and motor housing 21 provide ventilation of the motor 18 and sleeve bearing 46.

The motor 18 further includes a flux ring assembly, generally indicated at 48. The flux ring assembly 48 includes a flux ring 50 with the permanent magnets 33 fixed to the flux ring 50. In the illustrated embodiment, the flux ring 50 and magnets 33 are insert molded with respect to the motor housing 20. Thus, during a molding process the flux ring 50 and magnets are molded via plastic material to be integral with the housing 20. The insert molded flux ring 50 and magnets 33, and over-molded housing 20 advantageously eliminate the magnet-case subassembly and motor-shroud final assembly of the conventional cooling module.

The fan 16 is coupled to end 25 of the shaft 26 to rotate therewith. The motor 20 operates as a typical brush-type dc motor causing rotation of the armature assembly 28 and thus rotation of the fan 16.

In the conventional manner, the cooling module 10 of the invention can be mounted as a unit to be operatively associated with a radiator of a vehicle for cooling the engine of the vehicle. The cooling module of the invention is of reduced axial length as compared to conventional cooling modules. Advantageously, the reduced axial length cooling module of the invention does not consume as much valuable engine compartment space as does conventional cooling modules.

The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Therefore, this invention includes all modifications encompassed within the spirit of the following claims. 

What is claimed is:
 1. A method of providing an engine cooling module comprising: integrally coupling a motor housing to a shroud structure via a molding process, said housing having an open end, insert molding a heat sink with respect to said housing to be fixed thereto opposite said open end, said heat sink defining a bearing seat for a bearing of the motor, said bearing supporting a drive shaft, insert molding a flux ring assembly with respect to said housing so as to be fixed thereto, said flux ring assembly including permanent magnets, mounting an armature assembly and commutator for movement with said shaft in response to a magnetic field generated by said magnets, coupling a brush card assembly to said housing so as to cover said open end, said brush card assembly including brushes associated with said commutator, and coupling a fan to said shaft.
 2. The method according to claim 1, wherein said brush card assembly is snap-fitted to said housing. 